Estudo de caso de otimização topológica e estruturas celulares aplicadas à peça obtida por manufatura aditiva por extrusão de material

Abstract

With the advent and popularization of 3D printers in various industrial segments, additive manufacturing has become a strategic technology for the production of prototypes and final parts. This is due to its versatility in obtaining complex geometries without the need of procedures and tools which are required in conventional techniques. In this context, the structural optimization of components obtained by additive manufacturing becomes an important factor, considering that they will be subject to mechanical efforts that can compromise the lifespan and also that the material cost represents an important part in the final value of the component. The study of strength and functionality of these components is still little explored in engineering projects due to the high complexity in relating the manufacturing variables with structural analysis and optimization models. Topology optimization finds the best material distribution in a physical model, in order to maintain its functional integrity when subjected to mechanical loads. Therefore, the present work seeks to topologically optimize a part, manufacture it by additive manufacturing via material extrusion and compare it with parts made with different filling structures patterns, obtained by the same additive manufacturing principle, in order to reduce mass in relation to an initial part. The objective is to evaluate the mechanical behavior of the manufactured parts through bending tests. In order to validate the results, numerical models of parts manufactured by additive manufacturing were simulated by finite elements. Based on the results, it was verified that the topology optimization obtained a part with a better bending mechanical behavior when compared to the parts with cellular filling structures.